Plank forming systems

ABSTRACT

A method or device for creating a plank. The device may include a container with an opening to receive a material. The device may also include a beam extending from a side of the container to a point in an open space of the container. The beam may have a curved shape. A portion of the material may form around the beam.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of application Ser. No. 15/845,076, filed 18 Dec. 2017.

BACKGROUND

An outdoor deck may include planks that run along a top surface of a sub-frame to form a flooring for the outdoor deck. The planks of the outdoor deck may be interconnected to the sub-frame and each other when installed to provide a stable and secure platform for individuals to walk on or place objects on, such as furniture, grills, or decorations.

SUMMARY

A method, system, or device for creating a plank. The device may include a container with an opening to receive a material. The device may also include a beam extending from a side of the container to a point in an open space of the container. The beam may have a curved shape. A portion of the material may form around the beam.

BRIEF DESCRIPTION OF THE DRAWINGS

The present description will be understood more fully from the detailed description given below and from the accompanying drawings of various embodiments of the present embodiment, which is not to be taken to limit the present embodiment to the specific embodiments but are for explanation and understanding.

FIG. 1 illustrates a plank forming system for creating a plank with a curved channel or core, according to an embodiment.

FIG. 2A shows the mold device with multiple molding sections, according to an embodiment.

FIG. 2B shows the second mold with one or more beams, according to an embodiment.

FIG. 3 shows a side view of a plank created using plank forming system in FIG. 1, according to an embodiment.

FIG. 4 shows a side view of the plank connector connecting a first plank to a second plank, according to an embodiment.

FIG. 5 shows an outdoor platform with planks uniformly spaced apart from each other, according to an embodiment.

FIG. 6 shows a flowchart for a method of creating a plank with an hourglass hollow core, according to an embodiment.

DETAILED DESCRIPTION

The disclosed plank forming systems will become better understood through a review of the following detailed description in conjunction with the figures. The detailed description and figures provide merely examples of the various embodiments described herein. Those skilled in the art will understand that the disclosed examples may be varied, modified, and altered and not depart from the scope of the embodiments described herein. Many variations are contemplated for different applications and design considerations; however, for the sake of brevity, the contemplated variations may not be individually described in the following detailed description.

Throughout the following detailed description, examples of various plank forming systems are provided. Related features in the examples may be identical, similar, or dissimilar in different examples. For the sake of brevity, related features will not be redundantly explained in multiple examples. Instead, the use of related feature names will cue the reader that the feature with a related feature name may be similar to the related feature in an example explained previously. Features specific to a given example will be described in that particular example. The reader is to understand that a given feature need not be the same or similar to the specific portrayal of a related feature in any given figure or example.

Planks may be long, thin, flat pieces of material used in building a flooring of a building or an exterior platform. The exterior platform may be a deck, a patio, and so forth. Conventionally, the planks may be formed by shaping a board to the shape and size desired for the exterior platform. For example, the board may be a wood board that is milled, planed, and cut to a desired shape and size. When multiple boards have been shaped and sized, the boards may then be attached to a surface or sub-frame of a floor or exterior platform in rows or columns to form the flooring. Conventionally, the boards may be solid materials that are planed, milled, and cut into planks with desired lengths, widths, and thicknesses. As the conventional boards may be solid material, the boards may be relatively heavy. The heavy material may require that the frame and sub-frame of the exterior platform include more support structures and/or include sturdier material to support the weight of the planks. Additionally, the relatively heavy planks may be relatively costly to transport due to the weight of the material. Furthermore, the relatively heavy planks may be difficult for a builder of the flooring or exterior platform to carry and maneuver.

Conventionally, to reduce a weight of a plank, the plank may include channels or hollow cores that extend along an X-axis or a Y-axis of the plank. For example, a drilling device may drill a channel or core into the plank to remove a portion of the material of the plank to reduce a weight of the plank. As the drilling device removes the material to form one or more channels or hollow cores in the plank, the channels or hollow cores may be circular like a drill bit. However, the circular channels or cores may be a weak point in the plank that is prone to breaking. For example, as weight is applied to the plank at a circular channel or core, the plank may begin to flex and break at the circular channel or core because the circular channel or core may not be able to hold the weight being applied to the plank.

The embodiments described herein may address the above-noted deficiencies by providing a plank forming system to form a plank with one or more curved channels or cores from a material. The plank forming system may include a mold device with a container and a beam. As a material is received into the container, a portion of the material may form around the beam to form a plank with a curved channel or core. The plank with the curved channel or core may reduce a weight of the plank and while maintaining a relatively high weight/load distribution ratio.

FIG. 1 illustrates a plank forming system 100 for creating a plank with a curved channel or core, according to an embodiment. The plank forming system 100 may include a first container 102. In one example, the first container 102 may be a hopper of an extrusion machine. The first container 102 may include a first opening to a first opening to receive a material. In one embodiment, the material may be may be a granulated material. In one example, the material may be a granulated wood material, such as a granulated bamboo material, a granulated redwood material, a granulated cedar material, and so forth. In another embodiment, the granulated wood material may be granulated wood fiber material, such as a granulated bamboo fiber material, a granulated redwood fiber material, a granulated cedar fiber material, and so forth. In another embodiment, the material may be a granulated composite material, such as a granulated vinyl material, a granulated fiber material, a granulated fiberglass material, a granulated ceramic material, and so forth.

The first container 102 may include a second opening 106. In one example, the first container 102 may be connected to a second container 108 (also referred to as an extruder) and the second opening 106 in the first container 102 may provide or convey the material into a third opening 110 of the second container 108. The third opening 110 may be a first end of the second container 108 to receive the material from the second opening 106 of the first container 102. The second container 108 may include a fourth opening 112 at a second end of the second container 108. The second container 108 may also include a driver 114 to move the material from the third opening 110 to the fourth opening 112. In one example, the driver 114 may be a screw connected to a motor. The motor may rotate the screw and as the screw rotates, the screw may grab the material from the first end of the second container 108 and move the material to the second end of the second container 108.

The plank forming system 100 may include a heater 116 to heat up the material while the material is in the second container 108. In one example, the heater 116 may be integrated into the second container 108. In another example, the heater 116 may be a separate device that is attached to the second container 108. In another example, the heater 116 may be approximate or near the second container 108 and may apply heat to the second container 108 and increase a temperature of the material. The heater 116 may increase a temperature of the material to a melting point where the material may transform from a solid granulated material to a liquid material.

When the material has become a liquid material, the driver 114 may propel the liquid material out of the fourth opening 112 into a fifth opening 120 at a first end of a mold device 118. For example, the first end of the mold device 118 may be connected to the second end of the second container 108 and may receive the liquid material from the second container 108.

The mold device 118 may include a form with walls to shape the liquid material into a plank with a defined shape and size. In one example, the form may include walls to shape an exterior shape of the plank. In one embodiment, the defined shape may be a rectangular shape, a square shape, or another polygonal shape. In another example, the plank may have rounded edges or square edges.

As the liquid material cools in the mold device 118, the liquid material may solidify back into a solid material that is in the form of a plank. The mold device may include a sixth opening 122 at a second end of the mold device 118. The material may be pushed out of the sixth opening 122 of the mold device 118 into a cooling tank 124 (also referred to as a cooling bath). The cooling tank 124 may include a cooling agent. As the material is placed in the cooling tank 124, the cooling agent may reduce a temperature of the material to further solidify the material into a solid plank. In one example, the cooling agent may be water. In another example, the cooling agent may be ammonia, oil, minerals, and so forth.

When the material has cooled in the cooling tank 124 and fully formed into a plank, a cutting device may be used to cut the plank to a desired length. In one example, the cutting device may be a saw that may cut the plank to a standard length for a plank used for flooring or an exterior platform.

FIG. 2A shows the mold device 118 with multiple molding sections, according to an embodiment. Some of the features in FIG. 2A are the same or similar to some of the features in FIG. 1 as noted by same reference numbers, unless expressly described otherwise. The mold device 118 may include a mold head 226. The mold head 226 may connect to the second end of the second container 108. The mold head 226 may receive the material from the second container 108 and begin to form the material into a plank.

In one example, the driver 114 of the second container 108 in FIG. 1 may push the material into the mold device 118 at a defined pressure so that the mold device 118 forms the material into a plank at the defined pressure. For example, as the material is pushed into the mold device 118, the material may be pushed through the molding sections of the mold device 118 to form the plank.

The material may be a liquid material that cools to a defined temperature and solidifies into a plank around walls, beams, indents, and other shapes of the mold device 118. In one example, the mold device 118 may include a vacuum to remove bubbles in the liquid material. For example, as the mold device 118 receives the liquid material, the liquid material may have air bubbles that form in the liquid. The air bubbles may cause pockets in the material that may weaken a structure of a plank. To remove the air bubbles, the vacuum may suck the air bubble out of the liquid so that only the liquid is with the mold device 118.

In one example, the mold device 118 may include a first mold 227 with an opening that has an initial width and height. The first mold may begin to form the material into a plank with a defined width and thickness. For example, the opening of the first mold 227 may be approximately 140 millimeters (mm) wide and 26 mm tall to form a plank that is approximately 140 mm wide and 26 mm thick. The mold head 226 may include a second mold 228. The second mold 228 may include an opening with one or more beams 229 that extend from a middle portion of the second mold 228 toward an open space of the second mold 228 or the mold device 118, as further discussed and shown in FIG. 2B. As the material is pressed through the opening of the second mold 228, the material may be compacted or shaped around by the beams 229 to form channels or hollow cores within a middle portion of the plank. In one example, the channels or hollow cores may be approximately 13 mm in diameter.

The channels or hollow cores may be tunnels or passages that extend from a first end of the plank to a second end of the plank. The channels or hollow cores may reduce an overall amount of material used to form the plank and reduce a weight of the plank. As discussed below, the beams 229 may also have one or more defined shapes that define the corresponding shapes of the channels or hollow cores.

The mold device 118 may also include a third mold 230 with one or more beams 232 that extend from an edge or side of the third mold 230. In one example, a first one of the beams 232 may extend from a first side of an inner cavity of the third mold 230 to form a first indent or channel along a corresponding first side of the plank. In another example, a second one of the beams 232 may extend from a second side of an inner cavity of the third mold 230 to form a second indent or channel along a corresponding second side of the plank. The first indent or channel and the second indent or channel may provide indents or channels for fasteners to be inserted to connect the planks to a sub-frame of an exterior platform or flooring surface. In one example, the first indent or channel may have a height of approximately 6 mm and a depth of approximately 9 mm.

The mold device 118 may also include a fourth mold 234 with one or more hoses 236 that extend from a top or bottom of an inner cavity of the fourth mold 234. In one example, the hoses may be air hoses or vacuum hoses to remove air bubbles from the material. For example, the hoses 236 may be connected to a vacuum that sucks out any air within the material to remove the air bubbles.

The mold device 118 may also include a fifth mold 238 with one or more beams 240 that extend from a top surface and/or a bottom surface of an inner cavity of the fifth mold 238. In one embodiment, the beams 240 may extend from the top of the inner cavity of the fifth mold 238 to form indents or channels into a top surface of the plank. In one example, the indents or channels along the top surface of the plank may provide a texture to the top surface of the plank. The texture may provide an anti-slip gripping surface for the plank. In another example, the indents or channels along the top surface of the plank may provide passageways for water or other fluids to drain off the top of the plank.

In another embodiment, the beams 240 may extend from the bottom surface of the inner cavity of the fifth mold 238 to form indents or channels into a bottom surface of the plank. In one example, the indents or channels along the bottom surface of the plank may provide a texture to the bottom surface of the plank. The texture may provide an anti-slip gripping surface for the plank. In another example, the indents or channels along the bottom surface of the plank may provide passageways for water or other fluids to drain off the bottom of the plank. In one example, the indents or channels along the top surface and/or the bottom surface of the plank may have a width of approximately 2.9 mm and a depth of approximately 2.2 mm.

The mold device 118 may also include a sixth mold 242 with a smoothing device. The smoothing device may be sandpaper, abrasive material, polishing material, and so forth. The smoothing device may smooth one or more exterior surfaces of the plank and remove any stray debris from the exterior surfaces of the plank.

The number, shape, and order of the molds 228, 230, 234, 238, and 242 of the mold device 118 and/or the beams of the molds 228, 230, 234, 238, and 242 are not intended to be limiting and may vary based on a desired size and shape of the plank. For example, the mold device 118 may include a single mold to form the plank to a desired shape and size or multiple molds to form different portions of the plank to desired shapes and sized. In another example, the molds 228, 230, 234, 238, and 242 may not include any beams, may include one beam, or may include multiple beams. In another example, the molds 234 and 238 may sequentially come before the mold 230 to form the plank as it is pushed through the mold device 118. The sizes of the channels, cores, and indents of the plank formed by the molds 228, 230, 234, 238, and 242 of the mold device 118 and/or the beams of the molds 228, 230, 234, 238, and 242 are not intended to be limiting and may vary based on a size and shape of the plank.

As discussed above, when the mold device 118 has formed the plank to the desired size and shape, the plank may enter the cooling tank 124 of FIG. 1 to cool the material of the plank and solidify the material of the plank into a solid plank. In one example, the cooling agent of the cooling tank 124 may cool the material of the plank to a defined temperature to solidify the plank.

FIG. 2B shows the second mold 228 with one or more beams 229, according to an embodiment. Some of the features in FIG. 2B are the same or similar to some of the features in FIG. 2A as noted by same reference numbers, unless expressly described otherwise. As discussed above, the second mold 228 may include one or more beams 229. The beams 229 may extend from a side of the second mold 228 toward an open space of the second mold 228 or the mold device 118 in FIGS. 1 and 2A. In one example, the beams 229 may include a first beam 229 a, a second beam 229 b, a third beam 229 c, a fourth beam 229 d, a fifth beam 229 e, and a sixth beam 229 f. The beams 229 a-f may extend from the side of the second mold 228. The beams 229 a-f may be separated from each other at defined intervals to form multiple channels or hollow cores into a middle portion of the plank.

The beams 229 a-f may have a defined shape and size. In one example, the beams 229 a-f may be the same shape and size. In another example, one or more of the beams 229 a-f may be a first defined shape and size and one or more of the beams 229 a-f may be a second defined shape and/or size. In one embodiment, the beams 229 a-f may be curve shaped, where at least a portion the exterior edge of each beam 229 is rounded. In one example, the curved shape may be an oval shape, an oval shape with an indent, a square shape with an indent, or a circle shape with an indent. In another example, the curved shape may be an hourglass shape, where the beam is oval shaped with a first indent on a first side of the oval and a second indent on a second side of the oval. The hourglass shape may distribute a weight applied to a top of the plank relatively evenly and increase a weight to load distribution ratio of the plank. For example, as weight is placed on a top surface of the plank, the weight pushes down on the channels or hollow cores. As the weight pushes down on the channels or hollow cores, the indents of the house glass may flex inwardly to distribute the weight relatively evenly across the arches of the hourglass shaped channel or hollow core. A curved shaped channel or hollow core may support a greater amount of weight than a channel or hollow core with straight edges because the force on the curve squeezes, or compresses, the material in the arch, rather than bending the channel or core. The material of the plank may be stronger when compressed than when bent.

FIG. 3 shows a side view of a plank 302 created using plank forming system 100 in FIG. 1, according to an embodiment. The plank 302 may include a top surface 304, a bottom surface 306, a first side edge 308, and a second side edge 310.

The first side edge 308 and/or the second side edge 310 may include grooves 312. In one embodiment, a groove 312 may be located between the top surface 304 and the bottom surface 306 of the first side edge 308 and/or the second side edge 310 of the plank. The grooves 312 may be formed by the beams 232 of the third mold 230.

In one embodiment, the groove 312 may be located at the approximate midpoint between the top surface 304 and the bottom surface 306 of the first side edge 308 and/or the second side edge 310. In another embodiment, the groove 312 may extend longitudinally along the entire length of the first side edge 308 or the second side edge 310. In another embodiment, the groove 312 may extend longitudinally along a portion of the length of the first side edge 308 and/or the second side edge 310. For example, the groove 312 may be formed into the first side edge 308 or the second side edge 310 at one or more portions along the length of the first side edge 308 and/or the second side edge 310.

In another embodiment, the groove 312 may be substantially rectangular shaped in a lateral cross-section. In another embodiment, the groove 312 may be substantially square shaped, circular shaped, or polygonal shaped in the lateral cross-section.

In another embodiment, a middle portion 318 of the plank 302 may include one or more channels or hollow cores 316. In one example, the middle portion 318 may be an area surrounding a center of the plank 302. The channels or hollow cores 316 may be formed by the beams 229 of the second mold 228. A size and shape of the channels or hollow cores 316 may correspond to a size and shape of the beams 229 of the second mold 228. For example, when the beams 229 are hourglass shaped beams, the channels or hollow cores 316 may be hollow hourglass shaped passages that extend a partial length or a full length of the plank 302. For example, the channels or hollow cores 316 may extend from a first end of the plank 302 to a second end of the plank 302.

In another embodiment, the top surface 304 and/or the bottom surface 306 may include one or more grooves 314. In one example, the grooves 314 may be formed by the fourth mold 234 or the fifth mold 238. The grooves 314 may be channels or conduits that control the flow or direction of the fluid. For example, the grooves 314 may extend along the top surface 304 and/or the bottom surface 306 of the plank 302 to direct the fluid to drain between gaps or spaces between multiple planks 302 of an outdoor platform. The plank 302 may include a single groove or multiple grooves that run along the top surface 304 and/or the bottom surface 306 of the plank 302.

FIG. 4 shows a side view of the plank connector 400 connecting a first plank 402 to a second plank 404, according to an embodiment. The first plank 402 and the second plank 404 may be created using the plank forming system 100. The first plank 402 may include an opening or first groove 410 at one or more edges of the first plank 402. The second plank 404 may include an opening or second groove 412 at one or more edges of the second plank 404. The first groove 410 and/or the second groove 412 may be substantially similar to the groove 312 in FIG. 3. The plank connector 400 may include a first wing 416 and a second wing 418. The first wing 416 of plank connector 400 may be inserted into the first groove 410. The second wing 418 may be inserted into the second groove 412. The plank connector 400 may also include an arm 408 that may be located on either side of a body of the plank connector 400. The arm 408 may be inserted or located between the bodies of the first plank 402 and the second plank 404 to space the first plank 402 and the second plank 404 apart from each other by a defined distance. For example, the arm 408 may be inserted or located between the first plank 402 and the second plank 404 to space the first plank 402 apart from the second plank 404 by approximately a width of the arm 408.

The plank connector 400 may be connected to a joist 414 by inserting a fastener 406 into an opening of the plank connector 400. The plank connector 400 may connect to the joist 414 and may fasten down the first plank 402 and the second plank 404 to the joist 414. For example, when the plank connector 400 is fastened to the joist 414, the first wing 416 may be located within the first groove 410 to hold the first plank 402 against the joist 414 and the second wing 418 may be located within the second groove 412 to hold the second plank 404 against the joist 414. The order that the plank connector 400 is connected to the joist 414, the first wing 416 is inserted into the first groove 410, and the second wing 418 is inserted into the second groove 412 is not intended to be limiting. In one example, the plank connector 400 may be connected to the joist 414 prior to the first wing 416 and the second wing 418 being inserted into the first groove 410 and the second groove 412, respectively. In another example, the first wing 416 may be inserted into the first groove 410, the plank connector 400 may be connected to the joist 414 by the fastener 406, and then the second wing 418 may be inserted into the second groove 412. Additionally, as discussed above, the design of the plank connector 400 may be symmetrical such that the first wing 416 may be inserted into the second groove 412 and the second wing 418 may be inserted into the first groove 410.

FIG. 5 shows an outdoor platform 500 with planks 502 uniformly spaced apart from each other, according to an embodiment. The planks 502 may be created using the plank forming system 100 in FIG. 1. The outdoor platform 500 may include multiple planks 502 that may be disposed transversely across a sub-frame 504 (referred to hereafter as joists) of a structure, such as a patio or deck of a house. For example, the outdoor platform 500 may be an outside deck that extends from a house. The outside deck may include planks 502 that may be disposed transversely across the joists 504. For example, the planks 502 may run adjacent to each other and may be spaced apart at a defined distance. The planks 502 may also be referred to as boards or decking.

In one embodiment, the planks 502 may be spaced apart by a distance ranging from approximately one-eighth of an inch to approximately a half of an inch. In another embodiment, a spacing of the planks may be based on the environmental conditions that the outdoor platform 500 may be subjected. In one example, the planks 502 may be spaced relatively close together when the outdoor platform is located in a relatively dry environment with low annual rainfall and/or no snow. In another example, the planks 502 may be spaced relatively far apart when the outdoor platform is located in a relatively wet environment with high annual rainfall and/or snow.

In one embodiment, a plank 502 may be hardwood material, composite material, synthetic material, and so forth. In another embodiment, the plank 502 may be two inches thick, 4 inches wide and 8 feet long. Each joist 504 may be hardwood material, composite material, synthetic material, and so forth. Each joist 504 may include a top edge, a bottom edge, a front surface, and a rear surface. The top edge, the bottom edge, the front surface, and the rear surface may be substantially flat surfaces. In one example, a portion of the bottom surface of each plank 502 may rest on the top edge of one or more of the joists 504. In one embodiment, the joists 504 may be successively spaced apart from one another at defined distances. For example, the joists 504 may be spaced apart from each other by a distance of approximately 52 inches to 24 inches. The joists 504 may support one or more planks 502 that are disposed transversely across the top edges of the joists 504.

FIG. 6 shows a flowchart 600 for a method of creating a plank with an hourglass hollow core, according to an embodiment. The method may include receiving a material in a cavity through an opening in a mold head (block 610). The method may include forming the material around a curved beam and walls of the cavity (block 620). The method may include applying pressure and heat to the material to solidify the material into a plank (block 630). In one example, the curved beam may an hourglass shape that creates an hourglass hollow core in the plank.

The disclosure above encompasses multiple distinct embodiments with independent utility. While these embodiments have been disclosed in a particular form, the specific embodiments disclosed and illustrated above are not to be considered in a limiting sense as numerous variations are possible. The subject matter of the embodiments includes the novel and non-obvious combinations and sub-combinations of the various elements, features, functions and/or properties disclosed above and inherent to those skilled in the art pertaining to such embodiments. Where the disclosure or subsequently filed claims recite “a” element, “a first” element, or any such equivalent term, the disclosure or claims is to be understood to incorporate one or more such elements, neither requiring nor excluding two or more such elements.

Applicant(s) reserves the right to submit claims directed to combinations and sub-combinations of the disclosed embodiments that are believed to be novel and non-obvious. Embodiments embodied in other combinations and sub-combinations of features, functions, elements and/or properties may be claimed through amendment of those claims or presentation of new claims in the present application or in a related application. Such amended or new claims, whether they are directed to the same embodiment or a different embodiment and whether they are different, broader, narrower or equal in scope to the original claims, are to be considered within the subject matter of the embodiments described herein. 

1. A system, comprising: a first container comprising: a first opening to receive a material; and a second opening to provide the material into a second material; a second container, comprising: a third opening at a first end of the second container to receive the material from the second opening of the first container; a fourth opening at a second end of the second container; a screw to move the material from the third opening to the fourth opening; and a heater to heat the material to a first temperature to liquefy the material into a liquid material; and a mold device, comprising: a third container with a fifth opening to receive the liquid material; a first beam extending from a side of the third container to within an open space of the third container, wherein: the first beam is a curved shape; and a first portion of the material forms around the first beam; a second beam located along a first edge of the third container, wherein a second portion of the material forms around at least a portion of the second beam; and a third beam located along a second edge of the third container, wherein a third portion of the material forms around at least a portion of the third beam, wherein when the liquid material cools to a second temperature, the liquid material solidifies into a plank.
 2. The system of claim 1, wherein the first beam forms a curved shaped channel within a middle portion of the plank.
 3. The system of claim 1, wherein the second beam forms a first indent along a first edge of the plank.
 4. The system of claim 1, wherein the third beam forms a second indent along a second edge of the plank.
 5. The system of claim 1, wherein the curved shape is an hourglass shape.
 6. The system of claim 1, wherein the curved shape of the first beam forms a curved shape core in the plank to reduce a weight of the plank and increases a weight to load distribution ratio of the plank.
 7. The system of claim 1, wherein the curved shape of the first beam is an oval shape, an oval shape with an indent, a square shape with an indent or a circle shape with an indent.
 8. The system of claim 1, further comprising a fourth beam located within the open space of the third container, wherein: the fourth beam is the curved shape; and a fourth portion of the material forms around the fourth beam.
 9. The system of claim 1, further comprising a cooling tank to reduce a temperature of the plank to a third temperature.
 10. The system of claim 1, wherein the mold device receives the material at a defined pressure.
 11. A device, comprising: a container with an opening to receive a material; and a first beam extending from a side of the container to a first point in an open space of the container, wherein: the first beam is a curved shape; and a first portion of the material forms around the first beam.
 12. The device of claim 11, wherein the material is a liquid material and wherein the material cools to a defined temperature, the material solidifies into a plank around the first beam and walls of the container.
 13. The device of claim 11, further comprising a second beam located along a first edge of the container, wherein a second portion of the material forms around at least a portion of the second beam.
 14. The device of claim 11, further comprising a third beam located along a second edge of the container, wherein a third portion of the material forms around at least a portion of the third beam.
 15. The device of claim 11, wherein the curved shape is an hourglass shape.
 16. The device of claim 11, further comprising a second beam with the curved shape extending from a side of the container to a second point in the open space of the container.
 17. The device of claim 11, wherein the material is at least one of a granulated bamboo fiber or a granulated wood fiber.
 18. The device of claim 11, further comprising a vacuum to remove bubbles from the material.
 19. A method, comprising: receiving a material in a cavity through an opening in a mold head; forming the material around a curved beam and walls of the cavity; and applying pressure and heat to the material to solidify the material into a plank.
 20. The method of claim 19, wherein the curved beam is an hourglass shape that creates an hourglass core in the plank. 